Wearing well: new premium wear part solutions from Sandvik, Metso, Weir Minerals, and Haver & Boecker

Being able to quickly access and install high-performing replacement wear parts on quarrying plant minimises downtime leading to enhanced worksite efficiency.
Crushing Static & Mobile / July 7, 2020 3 mins Read
By Guy Woodford
Sandvik Optitooth kits come in three different offerings
Sandvik Optitooth kits come in three different offerings

A producer of high-quality crushers since 1896, Swedish quarrying plant manufacturer Sandvik says it has always taken great pride in its innovation and developing products which will improve its customers’ bottom line.

The company’s crushing chambers are based on quality products said to be built with superior finish and supported by in-depth knowledge of every aspect of the crushing process. “It is through this knowledge and expertise that we are able to understand the demands of our customers and develop high-performance wear parts, to ensure the reliable and smooth operation of Sandvik equipment throughout its entire lifecycle,” says Andrew Bolton, product line manager Tracked Mobiles, Sandvik Mobile Crushers and Screens.

Following the successful launch of Sandvik Optitooth jaw plates, Sandvik Mobile Crushers and Screens has now created a number of ready-to-order maintenance kits for Sandvik mobile jaw crushers. These have been designed to simplify customer service and increase maintenance efficiency. The tailor-made Optitooth kits are designed around the natural usage of the wear parts and offer all components a customer needs with just a single part number.

Metso’s Rotable Top Shells for Superior gyratory crushers are complete shell segments relined in advance (either on- or off-site) and ready to be installed
Metso’s Rotable Top Shells for Superior gyratory crushers are complete shell segments relined in advance (either on- or off-site) and ready to be installed

Key customer benefits are said to include easier and faster means of ordering replacement parts in one simple transaction; greater parts availability  – so customers avoid delays or parts shortages with the delivery of all components in one shipment; less downtime - with wear parts replaced in just one service interval; and improved profitability - as enhanced maintenance efficiency will, ultimately, boost customers’ bottom lines.

Sandvik Optitooth kits come in three different offerings. Optitooth Fixed Kit includes a fixed Optitooth jaw plate and lower cheek plates. Optitooth Swing Kit features a swing Optitooth jaw plate and lower cheek plates. And Optitooth Kit comprises one fixed and one swing Optitooth jaw plate along with upper and lower cheek plates.

All the necessary components are supplied with the kit to keep a customer’s crushing chamber operating at optimal performance.

“The new profile of jaw plate was designed for a higher percentage of the jaw to be utilised resulting in longer wear life and less manganese waste,” says Bolton. “The backing plate was redesigned to make it easier for removal, thereby reducing maintenance time and ultimately downtime, saving time as well as money.

“The improved profile also brings with it a number of additional benefits which all contribute to improved product shape. The unique profile was designed around the production of a more cubical material and reduction of elongated slab material which can cause blocking issues for secondary cone crushers.”  

Sandvik says customer feedback on the Optitooth kits has been extremely positive. Average jaw crusher output is said to have increased from 200 to 250 tonnes per hour and wear rates increased upwards of 30% (the test results should not be treated as specifications and Sandvik does not guarantee, warrant or represent the outcome of test results in any or all circumstances).

In addition to the increased wear performance, customers are also said to have seen benefits in relation to fuel economy — the improved transfer of material results in lower engine loading with faster material passage through the crushing chamber. Sandvik says results have proven savings of up to 15% less fuel (see above Sandvik comment on test results).

The improved design of the Optitooth jaw plate is said to allow for better breakage and improved material flow, resulting in a more cubical and higher quality product shape. The design is also said to make the plates easier to turn over or replace, saving customers time and money.

All of the above, says Sandvik, results in increased jaw crusher efficiency and higher productivity by up to 20% (see above Sandvik comment on test results).

Scottish quarrying customer G.F. Job is among those benefiting from the use of Sandvik Optitooth jaw plates. “They benefit us all round: we are crushing far more, getting better fuel economy, producing a better product and they last an awful lot longer,” says Graeme Watt, the company’s operations manager.

A Metso Rotable Top Shell in action  – ready to be installed during a planned shutdown at a Boral Australia gold and copper mine.
A Metso Rotable Top Shell in action  – ready to be installed during a planned shutdown at a Boral Australia gold and copper mine.

The Optitooth jaw plate has proved suitable for a wide range of applications, particularly abrasive quarry rock. It is fitted to all Sandvik Q-Range mobile jaw crushers as standard.

Sandvik always recommends using genuine spares and wear parts to ensure reliability and optimal performance of customers’ mobile equipment.

Metso’s Rotable Top Shell for all sizes of the company’s Superior primary gyratory crusher reduces crusher downtime thanks to speedier change-outs while, at the same time, increasing safety.

Most Rotable Top Shell-related work is  completed out of the line of fire. There is a large reduction in risk as more tasks are done in a controlled environment, and the actual relining process can even take place off-site. During the time-sensitive change-out period, there are fewer parts to lift and manipulate.  The solution includes hydraulic shell separators which also help to minimise human intervention.

By using the Rotable Top Shell’s additional shell segment(s), which are already inspected and lined prior to a shutdown, Metso claims a customer can save up to 45% in downtime for their primary gyratory crusher. This is exceptionally relevant to larger aggregates plant which are operating close to 24/7. However, this is also beneficial for plant which are not operating around the clock. As with this shorter window needed for shutdowns, most aggregates producers can fit the change-out in fewer shifts. Downtime can also be more easily scheduled either off-shift or during the off-season.

In addition to shorter shutdown, less manpower is needed for the complete Rotable Top Shell change-out process. This is said to provide added flexibility for operators who now have multiple options for relining which won’t affect operations. Producers have the choice to do the reline work themselves, on- or off-site, or with a 3rd party, again on- or off-site.

With a streamlined process, being mostly implemented outside of the critical shutdown path, costs are more predictable, making it easier to plan and manage budgets. Additionally, some traditional cost elements can be minimised further, such as crane rentals, which are typically rented/brought in specifically for relines.

The Metso Rotable Top Shell is a new concept/solution which has been introduced slowly over the last few years as a “complete” customer solution. Four mine sites are currently operating with it now, and a handful is said to be in the final consideration steps.

“This has not yet been formally introduced to the aggregates industry; however, the benefits and process are nearly identical to mining. With hundreds of Superior primary gyratory crushers currently in operation in aggregates industries around the world, this solution has great potential,” says Terry Galvin, Metso business development manager.

Weir Minerals’ Linard modular anti-abrasion panels
Weir Minerals’ Linard modular anti-abrasion panels

The Rotable Top Shell offers the most benefits to producers with a high wear rate on their primary gyratory crusher, where change-outs are happening regularly, i.e., hard and abrasive material, such as granite. Producers who operate a site close to an around-the-clock operation, have a lean maintenance staff, and have an older machine that they are currently considering for shell repairs will also, says Galvin, benefit greatly from using the Rotable Top Shell.

Additionally, given the smaller sized primary gyratory crushers present in the aggregates industry, the Rotable Top Shell can be a very affordable solution for sustaining capital.

“While there may be some suppliers offering additional shell segments in certain markets  –  as of today, we are the only OEM [original equipment manufacturer] with a complete solution for this – that we know of. We can offer end-to-end solutions (liners, installation, inspection programs, financing, online monitoring, etc.) – technical and commercial to fit individual producer’s operating budget,” Galvin added.

“We are currently evaluating and developing multiple complementary solutions. This includes applying our technology to other OEM primary gyratories, as part of our Metso Contender Series. This series of premium parts and solutions is specifically designed for non-Metso equipment in order to simplify the buying process for our customers.

“We are looking at supplying complementary products to make primary gyratory crusher shutdowns even safer and more efficient. This includes products such as fastening techniques, rigging techniques, and auxiliary components. We are also considering formalising similar concepts for our other crushing products, such as GP cone crushers.”

Inspired by key pain points Weir Minerals’ field staff observed across a range of mines and quarries, the company’s expert engineers have developed Linard modular anti-abrasion panels. The panels are said to provide a cost-effective and convenient solution for reducing downtime caused by high impact and abrasive wear in chutes and other applications in quarries and mines.

Boral Australia is among mining and quarrying companies currently using Weir Minerals’ Linard modular anti-abrasion panels
Boral Australia is among mining and quarrying companies currently using Weir Minerals’ Linard modular anti-abrasion panels

Available in 30mm and 50mm thickness, Linard modular anti-abrasion panels are ideally suited to minimising wear and maintenance in localised impact and wear points. The outstanding wear life is due to the wear material: Linard HD60 rubber in a rigid self-sealing construction with steel backing. The optional composite ceramic (92% alumina) or high-chromium white iron inserts add to the claimed extraordinary wear life of the panels.

“Our new Linard panels have been designed from the ground up to last in some of the most arduous wear applications. Depending on the customer’s needs, we offer composite panels with either ceramic or high chromium white iron inserts. They combine with our Linard HD60 rubber compound to deliver world-class impact and abrasion resistance in chutes, hoppers and under-pans,” says Mark Doyle, global product manager – Rubber, Spool and Hose for Weir Minerals.

Linard modular anti-abrasion panels are said by Weir Minerals to have improved wear life by ten times after replacing a competitor’s teflon wear panels in chutes across two quarries run by Boral Australia. This is said to have saved more than AU$12,000 per annum (US$7,950) in direct costs and led to a significant uptime increase due to a 90% reduction in shutdowns.

The 300mm² panels interlock to facilitate quick and easy installation and replacement while reducing the potential for fine material to ingress between the panels. Linard modular anti-abrasion panels are supplied in a convenient kit including a range of hold-down plugs. They can supply drawn arc studs which were needed to provide a convenient off-the-shelf but customisable solution to the application.

“Our engineers can replace these panels in minutes, reducing the amount of time they need to spend in chutes and other confined spaces. They are a bolt-in/bolt out solution and being modular they’re easy to fit onto any flat surface that requires extra protection. This also makes it easy to swap around composite and standard panels to ensure the highest wear areas are the best protected,” says Paul Duthy, Wear Solutions product manager, Weir Minerals.

Haver & Boecker Niagara is guaranteeing customers’ inventory through Make & Hold and Stocking Agreement programmes for screen media and wear parts. The programmes help mineral processing customers plan ahead and minimise downtime from long lead times while also providing options for pricing stability and simplified inventory management.

Haver & Boecker Niagara says it guarantees customers’ inventory through Make & Hold and Stocking Agreement programmes for screen media and wear parts
Haver & Boecker Niagara says it guarantees customers’ inventory through Make & Hold and Stocking Agreement programmes for screen media and wear parts

“We want to help ensure our customers have the screen media and parts they need to keep their equipment running and maximise production,” said Karen Thompson, president of Haver & Boecker Niagara’s North American and Australian operations. “That is why we provide Make & Hold and Stocking Agreements to help operations with inventory management and provide peace of mind.”

The Make & Hold programme guarantees customers the screen media and/or wear parts they require, and pricing is agreed upon at the beginning of the programme. Items are reviewed annually, and adjustments are made as needed. The manufacturer produces and packages the product in pre-determined quantities so it can be shipped the same day the order is placed. Stock is automatically replenished after shipment in preparation for the next time the customer requires it. The programme gives customers immediate access to items that would normally require longer lead times. Pricing is locked in, and the customer is only invoiced when the product ships.

Haver & Boecker Niagara also offers Stocking Agreements — or blanket orders — for customers interested in a one-time annual agreement. The pricing is locked in for the calendar year upon agreement for a pre-determined quantity of product. Customers pay per shipment as they draw from their stock as needed throughout the year. The product is shipped the same day the order is placed.

Both programmes are said to be an opportunity for operations to ensure product availability and price stability throughout the year and are particularly beneficial for products that may otherwise have extended lead times.

 

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